Multi-objective Optimization of Machining Non-circular Gears on Wire Electrical Discharge Machine Using the Overall Evaluation Index

In this paper, the objectives of tooth surface roughness and productivity of machining non-circular gears on wire electrical discharge machine are simultaneously optimized based on the overall evaluation index and the Taguchi method. The effect of machining parameters including the current, the cutting speed, and the winding speed on the overall evaluation index in the multi-objective optimization problem are evaluated based on the analysis of variance of experimental results. Analysis results show that the cutting speed has the most significant effect to the overall evaluation index at 67.47%. In contrast, the current and the winding speed have less and approximately the same effect on the overall evaluation index at 14.28 and 18.24%, respectively. This study has shown an effective criterion to solve the multi-objective optimization problem in machining non-circular gears on wire cutting machines.